US20140328042A1 - Power Supply Module - Google Patents

Power Supply Module Download PDF

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Publication number
US20140328042A1
US20140328042A1 US14/265,652 US201414265652A US2014328042A1 US 20140328042 A1 US20140328042 A1 US 20140328042A1 US 201414265652 A US201414265652 A US 201414265652A US 2014328042 A1 US2014328042 A1 US 2014328042A1
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Prior art keywords
power supply
coil
supply module
connector
integrated circuit
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Granted
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US14/265,652
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US10080297B2 (en
Inventor
Zhuo Wu
Douglas James Malcolm
Yanfei Liu
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Sumida Electric HK Co Ltd
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Sumida Electric HK Co Ltd
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Assigned to Sumida Electric (H.K.) Company Limited reassignment Sumida Electric (H.K.) Company Limited ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LIU, YANFEI, WU, Zhuo, MALCOLM, DOUGLAS JAMES
Publication of US20140328042A1 publication Critical patent/US20140328042A1/en
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/02—Arrangements of circuit components or wiring on supporting structure
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F27/292—Surface mounted devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/40—Structural association with built-in electric component, e.g. fuse
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F2017/048—Fixed inductances of the signal type  with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/0001—Technical content checked by a classifier
    • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/49147—Assembling terminal to base

Definitions

  • the present disclosure relates generally to the field of power supply, and specifically to a power supply module.
  • the traditional way for integrating a power supply module is that: the above electronic components are electrically connected together in advance, for example, all of the electronic components are mounted on a printed circuit board, and then encapsulated by resin from outside to form an integrated structure of the power supply module, as shown in FIG. 1 .
  • the electronic components such as inductance, capacitance, resistance, integrated circuit chip, are connected, these electronic components are mostly electrically connected together by a circuit design around ports of the integrated circuit chip.
  • an electronic part 40 (such as integrated circuit) is mounted on a component connection department 31 by electronic connection (equivalent to a First circuit design), the end of a winding of a coil 10 is electronically connected with different coil connection departments 32 (equivalent to a second circuit design), the multiple port electrodes 30 , the component connection department 31 and the coil connection departments 32 are integrally molded, and an electronic circuit module formed by pressing forming by a magnetic body 20 in the end.
  • the object of the present disclosure is to provide a power supply module and a method for manufacturing the same.
  • a power supply module includes:
  • a coil including a coil body and a connecting terminal
  • connection configured to be electrically connected with the coil and the electronic component
  • a magnetic conductor configured to enclose in and around the coil body and the electronic component
  • the connector is integrally formed with the integrated circuit chip when manufacturing the latter.
  • electronic components also include a resistor and/or a capacitor.
  • the connector includes a terminal configured to be electrically connected with external circuit.
  • the connector is a lead frame.
  • the magnetic conductor is formed from magnetic powder by an encapsulating approach.
  • the encapsulating approach can be molding or potting.
  • a method for manufacturing the power supply module includes the following steps:
  • the connector electrically connecting the connector with a coil and electronic components at least including an integrated circuit chip, wherein the coil includes a coil body and a connecting terminal;
  • the electronic components also include a resistance and/or a capacitance.
  • the connector is a lead frame.
  • the method also includes a step of cutting out the outer peripheral portion of the lead frame to make a terminal that can be used by a user.
  • the structure of the power supply module is more compact and can better meet the needs of the miniaturization design, which reduces material consumption, simplifies procedure, reduces production costs and improve the performance.
  • FIG. 1 is a sectional view for illustrating an electronic circuit module formation in the prior art.
  • FIG. 2 is a structural diagram for illustrating a power supply module according to one embodiment of the present disclosure.
  • FIG. 3 is a flow diagram or illustrating a method for manufacturing the power supply module according to one embodiment of the present disclosure.
  • FIG. 4 is a sectional view for illustrating a manufactured power supply module according to one embodiment of the present disclosure.
  • a power supply module is provided. As shown in FIG. 2 , in one embodiment of the present disclosure, the power supply module includes a coil, electronic components, a connector and a magnetic conductor.
  • the coil includes a coil body and a connecting terminal, and preferably, the coil is a hollow coil.
  • the coil is preferably made of a flat copper wire, a round copper wire or a wound wire of other shapes and is wound according to a certain number of turns and shape in advance.
  • the electronic components include at least an integrated circuit chip which is a unit module preferably integrated a MOSFET, a drive circuit, a pulse width modulator and a controller.
  • the electronic components also include a resistor, a capacitor or other electronic components.
  • One or more integrated circuit chips can be provided upon the demands in use.
  • the connector is electrically connected with the coil and the electronic components, for example, each connecting terminal of the coil can be respectively electrically connected with a corresponding terminal of the connector.
  • the connector is integrally formed with the integrated circuit chip when manufacturing the latter.
  • the connector is a lead frame, all the electronic components are electrically connected to the lead frame, and preferably, a part of the outer periphery of the lead frame corresponding to the connecting terminal of the coil, which is bent upward, is electrically connected with the connecting terminal of the coil. In this way, only one circuit design is needed in the present disclosure, one circuit design is saved compared with the prior art, so as to reduce material consumption.
  • the setting of the connector can reduce damage to the integrated circuit chip that the integrated circuit chip is not easily affected by external electromagnetic interference, so as to improve the electromagnetic interference performance with the proposed structure, effectively resolve the electromagnetic interference problem in an integrated circuit chip.
  • the integrated circuit will contact with the magnetic core and therefore, the heat from the integrated circuit can be transferred through the magnetic core to ambient. Therefore, the heat transfer characteristics can be improved.
  • the connector includes a terminal configured to be electrically connected to an external device.
  • the magnetic conductor encloses in and around the coil body and the electronic components.
  • the magnetic conductor is generally designed in a cuboid or cube shape, and also can be designed in a cylinder shape or other shapes upon the demands in use.
  • the magnetic conductor is formed from magnetic powder by molding, potting or other encapsulating approaches.
  • a manufacturing method for the power supply module is provided. As shown in FIG. 3 in one embodiment of the present disclosure, the method includes the following steps:
  • Step S 1 integrally forming a connector when manufacturing an integrated circuit chip.
  • the connector is a lead frame.
  • Step S 2 electrically connecting the connector with a coil and electronic components at least including an integrated circuit chip, where the coil includes a coil body and a connecting terminal.
  • the integrated circuit chip is a unit module integrating a MOSFET, a drive circuit, a pulse width modulator and a controller.
  • the electronic components also include a resistor, a capacitor or other electronic components.
  • each connecting terminal of the coil can be respectively electrically connected with a corresponding terminal of the connector that the coil and other electronic components can be connected into a whole circuit by the lead frame.
  • Step S 3 encapsulating the coil body and the electronic component with a magnetic conductor so that the magnetic conductor encloses in and around the coil.
  • the magnetic conductor is formed from magnetic powder by molding, potting or other encapsulating approaches, namely the whole circuit is covered by the magnetic powder in the way of molding or other encapsulating approaches to form an entirety.
  • the method also includes:
  • FIG. 4 is a sectional view illustrating a manufactured power supply module according to one embodiment of the present disclosure. It can be observed from FIG. 4 that, the integrated circuit chip is electrically connected with the lead frame, two connecting terminals (pins) of the coil are respectively electrically connected to the corresponding terminals of the lead frame, the whole circuit connected by the coil and the integrated circuit chip is covered by the magnetic powder in the way of molding or other encapsulating approaches, and the peripheral portion of the lead frame is cut off to form coils pin and IC pins that can be used by a user.
  • the power supply module of the present disclosure has the following advantages:

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Dc-Dc Converters (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Lead Frames For Integrated Circuits (AREA)

Abstract

A power supply module and a method for manufacturing the same are disclosed. The power supply module includes a coil including a coil body and a connecting terminal; electronic components at least including an integrated circuit chip; a connector configured to be electrically connected with the coil and the electronic component; and a magnetic conductor configured to enclose in and around the coil body and the electronic component, wherein the connector is integrally formed with the integrated circuit chip when manufacturing the latter. The present disclosure can make the structure of the power supply module be more compact to further meet the needs of miniaturization design, reduce material consumption, simplify procedure, and therefore reduce the production costs.

Description

    FIELD OF THE INVENTION
  • The present disclosure relates generally to the field of power supply, and specifically to a power supply module.
    • BACKGROUND OF THE INVENTION
  • In the field of electronic products, with the development of miniaturization and integration in the electronic industry, in order to provide an accurate voltage and an accurate current for an operation of an electronic product, electronic components such as inductance, capacitance, resistance and integrated circuit chip, are integrated into one power supply module, for example, Power Supply in Package, to perform voltage or current conversion, which is convenient for engineer to develop and for the customer to use.
  • The traditional way for integrating a power supply module is that: the above electronic components are electrically connected together in advance, for example, all of the electronic components are mounted on a printed circuit board, and then encapsulated by resin from outside to form an integrated structure of the power supply module, as shown in FIG. 1. When the electronic components such as inductance, capacitance, resistance, integrated circuit chip, are connected, these electronic components are mostly electrically connected together by a circuit design around ports of the integrated circuit chip. In the production process, two circuit design iterations are normally needed for the engineer, one is to design a lead frame in the integrated circuit and when the integrated circuits mold by a encapsulating approach, the outer peripheral part of the lead frame will be cut out to form a terminal for users, the other is to design a lead frame when inductance, capacitance, resistance and other electronic components are integrated with the integrated circuit. In addition, after the above electronic components mounted on a printed circuit board to form a power supply module, the printed circuit board needs to be provided with ports that can be used by a user. For example, in a patent JP2001386984, as shown in FIG. 1, an electronic part 40 (such as integrated circuit) is mounted on a component connection department 31 by electronic connection (equivalent to a First circuit design), the end of a winding of a coil 10 is electronically connected with different coil connection departments 32 (equivalent to a second circuit design), the multiple port electrodes 30, the component connection department 31 and the coil connection departments 32 are integrally molded, and an electronic circuit module formed by pressing forming by a magnetic body 20 in the end.
  • Therefore, if simply combining each electronic component and integrated circuit together to form a power supply module according to method in the prior art, it not only increases production materials so as to make the production process more complicate, but also causes waste and increased cost.
    • SUMMARY OF THE INVENTION
  • In order to solve the above problems in the prior art, the object of the present disclosure is to provide a power supply module and a method for manufacturing the same.
  • According to an aspect of the present disclosure, a power supply module includes:
  • a coil, including a coil body and a connecting terminal;
  • electronic components, including at least an integrated circuit chip;
  • a connection, configured to be electrically connected with the coil and the electronic component; and
  • a magnetic conductor, configured to enclose in and around the coil body and the electronic component,
  • wherein the connector is integrally formed with the integrated circuit chip when manufacturing the latter.
  • Preferably, electronic components also include a resistor and/or a capacitor.
  • Preferably, the connector includes a terminal configured to be electrically connected with external circuit.
  • Preferably, the connector is a lead frame.
  • Preferably, the magnetic conductor is formed from magnetic powder by an encapsulating approach.
  • Preferably, the encapsulating approach can be molding or potting.
  • According to another aspect the present disclosure, a method for manufacturing the power supply module includes the following steps:
  • integrally forming a connector when manufacturing an integrated circuit chip;
  • electrically connecting the connector with a coil and electronic components at least including an integrated circuit chip, wherein the coil includes a coil body and a connecting terminal; and
  • enclose in and around the coil body and the electronic component with a magnetic conductor.
  • Preferably, the electronic components also include a resistance and/or a capacitance.
  • Preferably, the connector is a lead frame.
  • Preferably, the method also includes a step of cutting out the outer peripheral portion of the lead frame to make a terminal that can be used by a user.
  • With the above technical solution or the present disclosure, the structure of the power supply module is more compact and can better meet the needs of the miniaturization design, which reduces material consumption, simplifies procedure, reduces production costs and improve the performance.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a sectional view for illustrating an electronic circuit module formation in the prior art.
  • FIG. 2 is a structural diagram for illustrating a power supply module according to one embodiment of the present disclosure.
  • FIG. 3 is a flow diagram or illustrating a method for manufacturing the power supply module according to one embodiment of the present disclosure.
  • FIG. 4 is a sectional view for illustrating a manufactured power supply module according to one embodiment of the present disclosure.
    •  DETAILED DESCRIPTION OF THE INVENTION
  • The present disclosure may be best understood by reference to the following description taken in conjunction with embodiments and reference to the accompanying drawings.
  • According to an aspect of the present disclosure, a power supply module is provided. As shown in FIG. 2, in one embodiment of the present disclosure, the power supply module includes a coil, electronic components, a connector and a magnetic conductor.
  • The coil includes a coil body and a connecting terminal, and preferably, the coil is a hollow coil.
  • The coil is preferably made of a flat copper wire, a round copper wire or a wound wire of other shapes and is wound according to a certain number of turns and shape in advance.
  • The electronic components include at least an integrated circuit chip which is a unit module preferably integrated a MOSFET, a drive circuit, a pulse width modulator and a controller. In another embodiment of the present disclosure, the electronic components also include a resistor, a capacitor or other electronic components.
  • One or more integrated circuit chips can be provided upon the demands in use.
  • The connector is electrically connected with the coil and the electronic components, for example, each connecting terminal of the coil can be respectively electrically connected with a corresponding terminal of the connector.
  • Wherein, the connector is integrally formed with the integrated circuit chip when manufacturing the latter.
  • In one embodiment of the present disclosure, the connector is a lead frame, all the electronic components are electrically connected to the lead frame, and preferably, a part of the outer periphery of the lead frame corresponding to the connecting terminal of the coil, which is bent upward, is electrically connected with the connecting terminal of the coil. In this way, only one circuit design is needed in the present disclosure, one circuit design is saved compared with the prior art, so as to reduce material consumption.
  • In addition, the setting of the connector can reduce damage to the integrated circuit chip that the integrated circuit chip is not easily affected by external electromagnetic interference, so as to improve the electromagnetic interference performance with the proposed structure, effectively resolve the electromagnetic interference problem in an integrated circuit chip. In addition, the integrated circuit will contact with the magnetic core and therefore, the heat from the integrated circuit can be transferred through the magnetic core to ambient. Therefore, the heat transfer characteristics can be improved.
  • In another embodiment of the present disclosure, the connector includes a terminal configured to be electrically connected to an external device.
  • The magnetic conductor encloses in and around the coil body and the electronic components. The magnetic conductor is generally designed in a cuboid or cube shape, and also can be designed in a cylinder shape or other shapes upon the demands in use.
  • In one embodiment of the present disclosure, the magnetic conductor is formed from magnetic powder by molding, potting or other encapsulating approaches.
  • According to another aspect of the present disclosure, a manufacturing method for the power supply module is provided. As shown in FIG. 3 in one embodiment of the present disclosure, the method includes the following steps:
  • Step S1, integrally forming a connector when manufacturing an integrated circuit chip.
  • Preferably, the connector is a lead frame.
  • Step S2, electrically connecting the connector with a coil and electronic components at least including an integrated circuit chip, where the coil includes a coil body and a connecting terminal.
  • The integrated circuit chip is a unit module integrating a MOSFET, a drive circuit, a pulse width modulator and a controller. In another embodiment of the present disclosure, the electronic components also include a resistor, a capacitor or other electronic components.
  • In one embodiment of the present disclosure, each connecting terminal of the coil can be respectively electrically connected with a corresponding terminal of the connector that the coil and other electronic components can be connected into a whole circuit by the lead frame.
  • Step S3, encapsulating the coil body and the electronic component with a magnetic conductor so that the magnetic conductor encloses in and around the coil.
  • In one embodiment of the present disclosure, the magnetic conductor is formed from magnetic powder by molding, potting or other encapsulating approaches, namely the whole circuit is covered by the magnetic powder in the way of molding or other encapsulating approaches to form an entirety.
  • If the connector is a lead frame, the method also includes:
  • cutting out the outer peripheral portion of the lead frame to make a terminal that can be used by a user.
  • FIG. 4 is a sectional view illustrating a manufactured power supply module according to one embodiment of the present disclosure. It can be observed from FIG. 4 that, the integrated circuit chip is electrically connected with the lead frame, two connecting terminals (pins) of the coil are respectively electrically connected to the corresponding terminals of the lead frame, the whole circuit connected by the coil and the integrated circuit chip is covered by the magnetic powder in the way of molding or other encapsulating approaches, and the peripheral portion of the lead frame is cut off to form coils pin and IC pins that can be used by a user.
  • Therefore, compared with the power supply module in the prior art as shown in FIG. 1, the power supply module of the present disclosure has the following advantages:
  • 1. making the structure more compact to better meet the needs of the miniaturization design; and
  • 2. reducing material consumption and simplifying procedure and therefore reducing production costs.
  • The embodiments are chosen and described in order to explain the basic idea of the disclosure and their practical application so as to activate others skilled in the art to utilize the disclosure and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present disclosure pertains without departing from its spirit and scope.

Claims (10)

What is claimed is:
1. A power supply module, comprising:
a coil, comprising a coil body and a connecting terminal;
electronic components, comprising at least an integrated circuit chip;
a connector, configured to be electrically connected with the coil and the electronic components; and
a magnetic conductor, configured to enclose in and around the coil body and the electronic component,
wherein the connector is integrally formed with the integrated circuit chip when manufacturing the latter.
2. The power supply module of claim 1, wherein the coil is a hollow coil.
3. The power supply module of claim 1, wherein the electronic components further comprises a resistance and/or a capacitance.
4. The power supply module of claim 1, wherein the connector comprises a terminal configured to be electrically connected to the external circuit.
5. The power supply module of claim 1, wherein the connector is a lead frame.
6. The power supply module of claim 1, wherein the magnetic conductor is formed from magnetic powder by an encapsulating approach.
7. The power supply module of claim 6, wherein the encapsulating approach is molding or potting.
8. A method for manufacturing the power supply module of claim 1, comprising:
integrally forming a connector when manufacturing an integrated circuit chip;
electrically connecting the connector with a coil and electronic components comprising at least an integrated circuit chip, wherein the coil comprises a coil body and a connecting terminal; and
enclose in and around the coil body and the electronic component with a magnetic conductor.
9. The method of claim 8, wherein the connector is a lead frame.
10. The method of claim 9, wherein the method further comprises:
cutting out the outer peripheral portion of the lead frame to make a terminal that can be used by a user.
US14/265,652 2013-05-03 2014-04-30 Power supply module Active 2035-01-16 US10080297B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CN201310160722.9 2013-05-03
CN201310160722 2013-05-03
CN201310160722.9A CN104135139B (en) 2013-05-03 2013-05-03 A kind of power supply module

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US20190269015A1 (en) * 2016-11-17 2019-08-29 Sony Corporation Electronic component, power supply device, and method of manufacturing coil

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TWI614777B (en) * 2015-12-18 2018-02-11 Thin inductor structure and manufacturing method
US12017294B2 (en) 2020-02-28 2024-06-25 The Esab Group Inc. Electromagnetic components cooling apparatus, method, and configuration
CN114334676B (en) * 2021-12-22 2023-11-21 深圳市沃芯半导体技术有限公司 Packaging method of power chip and corresponding packaging structure

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JP2003188023A (en) * 2001-12-20 2003-07-04 Toko Inc Electronic circuit module
US20040239467A1 (en) * 2003-05-28 2004-12-02 Cyntec Company Configuration and method for manufacturing compact high current inductor coil
US20090207574A1 (en) * 2008-02-18 2009-08-20 Cyntec Co., Ltd Electronic package structure
JP2010022098A (en) * 2008-07-09 2010-01-28 Murata Mfg Co Ltd Power conversion/transmission device and non-contact type charged device
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JP2011222598A (en) * 2010-04-05 2011-11-04 Shindengen Electric Mfg Co Ltd Method for manufacturing magnetic body substrate, magnetic body substrate, and electronic circuit module
JP2012234986A (en) * 2011-05-02 2012-11-29 Shindengen Electric Mfg Co Ltd Inductor-integrated lead frame, electronic circuit module and method for manufacturing the same

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190269015A1 (en) * 2016-11-17 2019-08-29 Sony Corporation Electronic component, power supply device, and method of manufacturing coil
US10917971B2 (en) * 2016-11-17 2021-02-09 Sony Corporation Electronic component, power supply device, and method of manufacturing coil

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CN104135139B (en) 2018-01-26
US10080297B2 (en) 2018-09-18

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